Method and system for forming a road base

ABSTRACT

A system, kit and method for forming a reinforced road base wherein the system comprises an outer barrier having an upright portion forming a wall, a deadhead located inward on the road base of the outer barrier and at least one brace extending between the outer barrier and the deadhead, wherein each of the outer barrier, deadhead and at least one brace include metal connecting plates aligned with each other and operable to be welded together. The method comprises locating the outer barrier along an edge of the road base to be formed, locating a deadhead inward of the outer barrier along the road base, spanning between the outer barrier and the deadhead with at least one brace and securing the brace to the deadhead and the outer barrier by welding connecting therebetween.

BACKGROUND 1. Technical Field

This disclosure relates generally to road construction and in particular to a method and system for forming a road base of a plurality of connected modular components.

2. Description of Related Art

Roads are commonly formed by forming one or more substrate or base layers below a pavement or concrete covering. Common materials for such substrates may be crushed stone or the like. Disadvantageously, it has been found that such substrates of crushed rock or dirt may be prone to being washed away under higher volumes of running water such as during the spring. In such circumstances, the substrate and the entire roadway may be prone to washing out thereby destroying the roadway.

One common method to repair a washed out roadway is to remove and replace the existing substrate with added drainage culvers or diversions to prevent future occurrences of the wash-out. Such replacement however is expensive and time consuming requiring the entire roadway at that location to be removed and replaced. It will be appreciated that for some locations, this may require removal to a significant depth.

SUMMARY OF THE DISCLOSURE

According to a first embodiment, there is disclosed a system for forming a reinforced road base comprising an outer barrier having an upright portion forming a wall, a deadhead located inward on the road base of the outer barrier and at least one brace extending between the outer barrier and the deadhead, wherein each of the outer barrier, deadhead and at least one brace include metal connecting plates aligned with each other and operable to be welded together.

Each of the outer barrier, deadhead and at least one brace may be formed of concrete. The metal connecting plates may be cast into the outer barrier, deadhead and at least one brace. The deadhead may have a length less than the outer barrier.

The outer barrier may include connection plates for securing to a connection member spanning to an adjacent outer barrier so as to form a continuous barrier therewith. The connection member may be formed of metal. The connection member may be secured to the connection plates by welding.

The outer barrier may include an upright portion and a perpendicularly extending base portion. The at least one brace may rest on the base portion. The base portion may include at least one drain passage extending therethrough.

The at least one brace may include a middle portion having a bottom shaped to have an elevation above a bottom edge of the outer barrier. The deadhead may be secured to the outer barrier with two braces. The deadhead may be substantially parallel to the outer barrier.

According to a further embodiment, there is disclosed a kit for forming a reinforced road base comprising at least two outer barriers having an upright portion forming a wall, at least two deadheads each corresponding to and located inward on the road base of one of the at least two outer barrier, at least one brace extending between each of the at least one outer barrier and its corresponding deadhead, wherein each of the outer barrier, deadhead and at least one brace include metal connecting plates aligned with each other and operable to be welded together and at least one connection member operable to be welded to connection plates on the at least two barriers so as to connect the at least two connection barriers together.

According to a further embodiment, there is disclosed a method for forming a road base comprising locating at least one outer barrier along an edge of the road base to be formed, locating a deadhead inward of the outer barrier along the road base, spanning between the outer barrier and the deadhead with at least one brace and securing the at least one brace to the deadhead and the outer barrier by welding connecting plates on each of the outer barrier, deadhead and at least one brace together.

The method may further comprise locating a quantity of aggregate rock between the at least one outer barrier and the at least one brace. The method may further comprise locating a fabric barrier over the gravel.

Other aspects and features of the present disclosure will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments in conjunction with the accompanying figures.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings constitute part of the disclosure. Each drawing illustrates exemplary aspects wherein similar characters of reference denote corresponding parts in each view,

FIG. 1 is a perspective view of a system for forming a roadway according to a first embodiment of the present disclosure as located under a roadway.

FIG. 2 is a perspective view of the outer member of the system of FIG. 1 .

FIG. 3 is a perspective view of the deadhead of the system of FIG. 1 .

FIG. 4 is a perspective view of one of the connectors of the system of FIG. 1 .

FIG. 5 is a perspective view of the system of FIG. 1 being utilized to form a roadway at a first stage.

FIG. 6 is a perspective view of the system of FIG. 1 being utilized to form a roadway at a second stage.

FIG. 7 is a perspective view of the system of FIG. 1 being utilized to form a roadway at a third stage.

FIG. 8 is a perspective view of the system of FIG. 1 being utilized to form a roadway at a fourth stage.

DETAILED DESCRIPTION

Aspects of the present disclosure are now described with reference to exemplary apparatuses, methods and systems. Referring to FIG. 1 , an exemplary system for forming a roadway according to a first embodiment is shown generally at 10. The system 10 comprises a plurality of outer barrier members 12 connected endwise to each other to form a barrier for constraining a portion of soil under the roadway 8. The system further includes a deadhead and at least one brace (not shown in FIG. 1 ) corresponding to each of the outer barrier members 12.

Turning now to FIG. 2 , a rear perspective view of the outer member 12 is shown. The outer member comprises an elongate planar member having front and rear surfaces, 14 and 16, respectively and extending between first and second ends, 18 and 20, respectively and a top and bottom edge, 22 and 24, respectively. The front surface 14 is utilized to form an outside surface of the a roadway base as illustrated in FIG. 1 and may optionally include an aesthetic or textured surface as desired by a user.

The outer member 12 includes a base portion 30 extending perpendicular to the outer member 12 away from the rear surface 16 proximate to the bottom edge 24. The base portion 30 provides a wider base for maintaining the outer member 12 in an upright orientation in use. The base portion 30 extends to a free distal edge 32 and may optionally include one or more drainage ports 34 extending therethrough.

The outer member 12 may be formed of any suitable material, including concrete, composite materials, metals, woods, or the like so as to provide sufficient strength to retain a quantity of soil therebehind and includes a plurality of welding plates embedded there for connecting to the braces 80 as will be set out below. In particular, the rear surface 16 of the outer member 12 may include end connection plates 40 proximate to the first and second ends and a plurality of brace connection plates 42. The brace connection plates 42 are located at positions corresponding to the desired location of the braces 80. As illustrated in FIG. 2 , the brace connection plates 42 may be arranged in pairs so as to be located on each side of the desired location of the braces 80. The base portion 30 may also include one or more base brace connection plates 44 in the distal end surface 32 for connection to the brace at positions similar to the brace connection plates 42.

The first and second ends 18 and 20 may each include a vertical step 19 and 21, respectively into the first ends so as to enable adjacent outer members to be overlapped and interconnected with each other. In particular, the first end step 19 may be formed into the front face 14 whereas the second end step 21 may be formed into the rear face 16 such that the first and second end steps of adjacent member may be overlaid on each other to form a continuous barrier as illustrated in FIG. 1 . Optionally the top edge 22 may include weld plates 41 or bores 45 for securing a guard rail, walking path forming body oor the like to. Optionally, the weld plates 41 or similar plates may also be utilized to secure stacked outer members together to form a wall comprising multiple layers.

Turning now to FIG. 3 , a deadhead 50 for use with an outer member 12 is illustrated. The deadhead 50 comprises an elongate planar member having front and rear surfaces, 52 and 54, respectively and extending between first and second ends, 56 and 58, respectively and a top and bottom edge, 60 and 62, respectively. The front surface 52 is oriented towards the outer member as will be more fully set out below. The height of the front surface 56 may be selected to correspond to the needs of the roadway and may include shorter heights for use in forming a causeway or the like. The deadhead 50 includes a base portion 70 extending perpendicular to the deadhead 50 away from the front surface 52 proximate to the bottom edge 62. The base portion 70 provides a wider base for maintaining the deadhead 50 in an upright orientation in use and extends to a free distal edge 72. The deadhead 50 may have a length between the first and second ends 56 and 58 selected to be less than the length of the outer member 12. In such a manner, the deadhead 50 will not interfere with any angular relationship between the outer members 12 as illustrated in FIG. 1 . Although the outer member 12 are illustrated as substantially straight, it will be appreciated that curved or other shape may also be provided to form a roadway or path having the desired route. Additionally, the outer member 12 may be formed as a corner unit having intersecting portions at any desired angle.

The deadhead 50 may be formed of any suitable material, including concrete, composite materials, metals, woods, or the like and includes a plurality of welding plates embedded there for connecting to the braces 80 as will be set out below. In particular, the front surface 52 of the deadhead 50 may include end a plurality of brace connection plates 64. The brace connection plates 64 are located at positions corresponding to the desired location of the braces 80. As illustrated in FIG. 2 , the brace connection plates 64 may be arranged in pairs so as to be located on each side of the desired location of the braces 80. The base portion 70 may also include one or more base brace connection plates 74 in the distal end surface 72 for connection to the brace at positions similar to the brace connection plates 64.

Turning now to FIG. 4 , the brace 80 comprises an elongate member extending between first and second ends 82 and 84, respectively and top and bottom edges, 86 and 88, respectively. The brace 80 may be formed as a planar member having first and second sides 90 and 92. The brace 80 may be formed of any suitable material, including concrete, composite materials, metals, woods, or the like so as to provide sufficient strength to retain the outer member 12 and the deadhead 50 in the desired locations. It will be appreciated that the length of such brace 80 may be adjustable to as to accommodate roadways and paths of differing widths. Additionally, although the bottom edges of the brace is shown as substantially level, the notches 96 and 98 may be horizontally offset from each other so as to permit locating the deadhead at a higher height than the outer wall for passing over bedrock or other in ground obstructions.

The sides of the brace include connecting plates 94 at locations corresponding to the brace connection plates 42, 44, 64 and 74 on the outer member 12 and deadhead 50. Accordingly, once the brace 80 is located at the desired positions between the brace connection plates, connectors, such as, by way of non-limiting example, metal bars or the like may be welded between the plates so as to secure the brace to the outer member 12 or deadhead 50. As illustrated In FIG. 4 , the bottom edge 88 may include notches 96 and 98, respectively proximate to the first and second ends 82 and 84. The shape of the notches 96 and 98 correspond to the shape of the base portion 30 and 70 so as to permit the base portions to be received therein. The bottom edge 88 may also include a recessed middle portion 100 so as to permit water to pass thereunder assisting with drainage of the system.

In operation, a plurality of the outer members 12 may be located on a ground surface 6 to define an outer location of the roadway to be formed. As illustrated in FIG. 5 , the end connection plates 40 may be secured together by securing, by welding or other suitable means, an end connector 110 therebetween. As illustrated the outer members 12 may be angularly oriented relative to each other as desired for the shape and outline of the roadway. Thereafter, a deadhead 50 may be located parallel to and spaced apart from each outer member 12 as illustrated in FIG. 5 . Once the deadheads 50 are located in the desired position, the braces 80 may be located therebetween so as to abut the ends of the braces against the outer member 12 and the deadhead at positions between the plates. Brace connectors 112 may then be secured between the metal plates on the outer member or deadhead and the brace as illustrated by welding or the like as illustrated in FIG. 7 . Once the braces are connected to the outer members and the deadhead, gravel 122 or other well draining fill may be located within a region 120 between the braces and thereafter optionally covered with water permeable fabric 124, felt or the like. Although the present system is illustrated with a single deadhead and two braces for each outer member, it will be appreciated that other combinations may be useful as well, such as, by way of non-limiting example, a single deadhead for each brace and/or the use of one brace for each outer member. It will also be appreciated that by providing the above securing structures to the outer member 12, that the bottom outside edge of the outer member 12 may be cantilevered outwardly from the ground or other structure on which it is place.

While specific embodiments have been described and illustrated, such embodiments should be considered illustrative only and not as limiting the disclosure as construed in accordance with the accompanying claims. 

What is claimed is:
 1. A system for forming a reinforced road base comprising: an outer barrier having an upright portion forming a wall; a deadhead located inward on the road base of the outer barrier; and at least one brace extending between the outer barrier and the deadhead, wherein each of the outer barrier, deadhead and at least one brace include metal connecting plates aligned with each other and operable to be welded together.
 2. The apparatus of claim 1 wherein each of the outer barrier, deadhead and at least one brace are formed of concrete.
 3. The apparatus of claim 2 wherein the metal connecting plates are cast into the outer barrier, deadhead and at least one brace.
 4. The apparatus of claim 1 wherein the deadhead has a length less than the outer barrier.
 5. The apparatus of claim 1 wherein the outer barrier includes connection plates for securing to a connection member spanning to an adjacent outer barrier so as to form a continuous barrier therewith.
 6. The apparatus of claim 5 wherein the connection member is formed of metal.
 7. The apparatus of claim 6 wherein the connection member is secured to the connection plates by welding.
 8. The apparatus of claim 1 wherein the outer barrier includes an upright portion and a perpendicularly extending base portion.
 9. The apparatus of claim 8 wherein the at least one brace rests on the base portion.
 10. The apparatus of claim 8 wherein the base portion includes at least one drain passage extending therethrough.
 11. The apparatus of claim 1 wherein the at least one brace includes a middle portion having a bottom shaped to have an elevation above a bottom edge of the outer barrier.
 12. The apparatus of claim 1 wherein the deadhead is secured to the outer barrier with two braces.
 13. The apparatus of claim 1 wherein the deadhead is substantially parallel to the outer barrier.
 14. A kit for forming a reinforced road base comprising: at least two outer barriers having an upright portion forming a wall; at least two deadheads each corresponding to and located inward on the road base of one of the at least two outer barrier; at least one brace extending between each of the at least one outer barrier and its corresponding deadhead, wherein each of the outer barrier, deadhead and at least one brace include metal connecting plates aligned with each other and operable to be welded together; and at least one connection member operable to be welded to connection plates on the at least two barriers so as to connect the at least two connection barriers together.
 15. A method for forming a road base comprising: locating at least one outer barrier along an edge of the road base to be formed; locating a deadhead inward of the outer barrier along the road base spanning between the outer barrier and the deadhead with at least one brace; and securing the at least one brace to the deadhead and the outer barrier by welding connecting plates on each of the outer barrier, deadhead and at least one brace together.
 16. The method of claim 15 further comprising locating a quantity of aggregate rock between the at least one outer barrier and the at least one brace.
 17. The method of claim 16 further comprising locating a fabric barrier over the gravel. 